Installation method and installation receptacle for cabriolet roofs

ABSTRACT

A method and tool for mass manufacturing convertible roofs having an outer shell, a frame and lateral linkage parts for supporting the outer shell, the outer shell including at least two outer shell parts is provided. The method includes the steps of providing an upper tool fixture and a lower tool fixture, aligning and assembling the frame and outer shell in the lower tool fixture such that the frame and outer shell are upside down, aligning and assembling connection members onto the frame part so the roof can fittingly engage the windshield frame when the roof is in a closed position, and lowering the lateral linkage parts onto the assembled frame and outer shell using the upper tool fixture.

The invention relates to a method for the manufacture of convertibleroofs in accordance with the preamble of claim 1, to a tool inaccordance with the preamble of claim 9, to a roof installation tool inaccordance with the preamble of claim 16 and to a roof closureinstallation tool in accordance with the preamble of claim 22.

It is necessary in the manufacture of convertible roofs to observe ahigh dimensional precision to be able to carry out the insertion of theroof into the body carcass with an exact fit—and thus also in atime-saving manner in ongoing production.

However, this is difficult due to the inner spaces to be spanned by theroofs and to the plurality of mutually movable parts so that it isusually necessary to carry out an alignment of the roof on its insertionat the body carcass and, where necessary, to compensate tolerances byinterposing shims or similar tolerance-compensating measures between thebody and the roof. In addition, with roofs with at least one window, forinstance a rear window, there is already a high imprecision in thewindow manufacture which has to be taken into account and which caneasily add up to two millimeters.

It is the underlying problem of the invention to improve the manufactureof convertible roods which include one or more windows.

The invention solves this problem by a method having the features ofclaim 1 and by a tool having the features of claim 9, a roofinstallation tool having the features of claim 16 and a roof closureinstallation tool having the features of claim 22. Reference is made tothe further claims 2 to 8, 10 to 15, 17 to 21 and 23 to 25 with respectto advantageous aspects of the invention.

An exactly fitting and always constant alignment of the window to aframe part of the roof supporting it in the connection position is madepossible by the method in accordance with the invention. The alignmentof the parts is not carried out manually so that any installationimprecision in this respect is avoided. The spacing between the twoparts is preset by the two receiving planes fixed with respect to oneanother and is always constant.

Pushing members can in particular be associated with the window on thefirst contact plane such that they align the window toward an abutment,with the pushing path being dependent on the extent of the respectivewindow. Tolerances in the window size can thus be compensated by thedifferent pushing paths, with an always constant position of each windowat at least one edge nevertheless being ensured by the pushing againstthe abutment.

It is also particularly favorable for the spacing between the twocontact planes to be set such that an applied adhesive bead is squeezedin a defined manner and thus has sealing contact to the window and tothe frame part at every point. Since the parts are fixedly supported inthe receiving planes, it is nevertheless ensured that the full weightforce of one of the parts at no time bears down on the adhesive bead. Itis in particular helpful for this purpose if the window(s) and framepart(s) connected to one another in this manner remain in these planes,are movable in a defined manner therein and can be supplied to a furtherroof installation tool. The adhesive then has a longer period availablefor hardening before the parts connected in this manner are first movedrelative to one another.

A multipart roof can also be installed using the invention which, forexample, includes a frame part for the rear window and a frame partwhich is arranged at the front in the direction of travel and which cansupport a solid roof part or can be covered together with the rearwindow frame by a covering. The two frame parts can be installed at anangle which exactly corresponds to their angular position with a closedroof. All the mounted parts such as also front closure parts or laterallinkage parts can be installed thereat in an overhead position.

A connection of the frame parts to lateral linkages which are suppliedfrom above is in particular also possible in an ergonomically favorableand less irksome work posture of the operator. These linkage parts canfavorably be positioned in an upper support of a roof installation toolfree of tolerance in accordance with the body dimensions and can bemoved exactly by a downward movement of this support into a relativeposition with respect to the frame parts in which they are also locatedwith a later fully installed roof. A tolerance compensation in theinstallation of the roof to the body carcass is then no longer required.It is rather the case in a method shown here that a possible tolerancecompensation is possible within the installed roof: Shim packets ofdifferent thickness can be installed between the linkage parts, on theone hand, and the frame parts with installed windows, on the other hand,said shim packets additionally also having elongate holes in addition tothe thickness adjustability and so being able to compensate tolerancesin two spatial directions. No tolerance compensation is necessary in thethird spatial direction, in contrast, since upper and lower supports inthe tool can be moved toward one another to a precisely matchingvertical spacing.

Front connection members in the fixedly aligned holder of the frameparts can also advantageously be set onto the front roof end in anautomatedly aligned manner by means of a pivot template or a similarlymovable template. The hardening period for the adhesive before theremoval of the window(s) and frame part(s) is thus further extended; theroof can be removed from the tool in the completely installed positionwith an exact fit with respect to the body.

The tool for the connection of window(s) and frame part(s) with aholding of the parts spaced apart in a defined manner, the roofinstallation tool for the supply of the lateral linkage parts laterholding the roof and the roof closure installation tool for theautomatically aligned attachment of the connection members of the rooftip are likewise integral parts of the application and are also claimed.

Further advantages and features of the invention result from anembodiment of the subject matter of the invention shown schematically inthe drawing and described in the following.

There is shown in the drawing:

FIG. 1 to FIG. 4: a schematic procedure of a part of the method inaccordance with the invention; therein:

FIG. 1 the insertion of two windows later forming the outer skin of theroof into a tool providing two receiving planes;

FIG. 2 the alignment of the rear window by pushing members at the edge;

FIG. 3 the placing of frame parts provided with adhesive beads onto thesecond receiving plane;

FIG. 4 the guiding of lateral linkage parts to the frame parts connectedto the windows;

FIG. 5 a perspective view of the tool shown schematically in FIG. 1before its equipping with parts of the roof;

FIG. 6 a similar view to FIG. 5 after fitting of a part of the tool witha window of the roof larger engaging over a passenger compartment;

FIG. 7 a similar view to FIG. 6 with a second window additionallyinserted into the first receiving plane and aligned via pushing members,approximately corresponding to the position in accordance with FIG. 3;

FIG. 8 a similar view to FIG. 7 with a frame part which is placed ontothe second support plane and is adhesively bonded to the first window;

FIG. 9 a similar view to FIG. 8 with a frame part also placed onto thesecond receiving plane over the rear window for adhesion;

FIG. 10 the tool equipped in accordance with FIG. 9 in a side view;

FIG. 11 a detailed view obliquely from above of the frame parts clampedimmovably;

FIG. 12 a schematic and substantially lateral view of a roofinstallation tool in which the advanced tool in accordance with FIG. 10forms a lower support and in which an upper support holds laterallinkage parts, approximately corresponding to the position in accordancewith FIG. 4;

FIG. 13 a similar view to FIG. 12 during the installation of the laterallinkage parts to a frame part;

FIG. 14 a similar view to FIG. 14 on the upward movement of the uppersupport after completion of the installation of the linkage parts;

FIG. 15 a detailed view from above of the connection between the linkageparts and the frame part in the tool with washers of a shim packetplaced therebetween.

The tool 1 shown schematically in FIG. 1 and in detail in FIG. 5 has afirst receiving plane for outer skin parts 2, 3 of a convertible roof tobe manufactured and, spaced apart thereabove, a second receiving planefor frame parts 4, 5 supporting these outer skin parts 2, 3.

At least one outer skin part is here formed by a rear window 2. Afurther outer skin part 3 is here likewise formed by a window whichshould cover the passenger compartment of the vehicle with a closedroof. Precisely two outer skin parts 2, 3 are shown in the embodiment.Further outer skin parts can, however, be provided in dependence on thesize of the passenger compartment to be engaged over.

Nor must all the outer skin parts be made rigidly, but rather, inaddition to a rear window 2, a cover can, for example, also be providedwhich is connected to the frame parts 4, 5 via the method in accordancewith the invention. This can therefore be used both for retractable hardtops (RHTs) and for soft tops.

The first receiving plane, which serves for the receiving of the rearwindow 2 and the window 3 arranged at the front in the drawing isdefined by upwardly projecting supports 6 onto which the windows 2, 3can be placed in an position turned upside down, that is with the laterouter side facing downwardly. Abutments 7 are provided in the separationregion of the two windows and their thickness presets the spacing of thewindows at the assembled roof.

As can, for example, be seen in FIG. 2, pushing members 9 are providedfor at least one of the windows 2, 3 which set this window 2 preciselyagainst the abutments 7 with a variable travel path in the direction ofthe arrow 8 and hold it clamped thereagainst. Size differences of thewindow 2 caused by manufacture can be compensated in this process by thevariable travel path.

The windows 2, 3 or other outer roof skin parts then contact at leastthe abutments 7 in a position in this tool 1 practically free oftolerance with respect to the tool 1. In this connection, they can bedisposed angled with respect to one another and have the angle to oneanother which corresponds to their angle to one another with a closedroof in the vehicle. The receiving planes are each angled for thispurpose.

The tool 1 furthermore includes a second receiving plane which is abovethe first and which serves in the drawing for the receiving of frameparts 4, 5 of the roof to be connected to the windows 2, 3. This secondreceiving plane is defined by outer upwardly projecting supports 10 ontowhich frame parts 4, 5 can be placed, for example, by being supplied bymeans of a robot arm. Furthermore, movable closures 11, here pivotableclosures, (not drawn in FIGS. 1 to 4) are associated with the supports10 and pivot over the frame parts 4, 5 and therefore align and securethem on the supports 10. Supports 10 and closures 11 form firmly fixingholders for the frame parts 4, 5. The frame parts 4, 5 like the windows2, 3 are likewise exactly alignable to the tool 1.

The windows 2, 3 or, here, the frame parts 4 5, are provided, beforebeing placed on, with a uniform adhesive bead 12 peripherally which has,for example, a triangular cross-section design with a height of one to1.5 centimeters. This adhesive bead is defined by the placement of theframe parts 3, 4 onto the supports 10 and is compressed uniformly downto a height of, for example, 5 to 8 millimeters due to the parallelposition of the receiving planes. The outer skin parts 2, 3 and theframe parts 4, 5 are firmly fixed with respect to one another duringthis procedure. The weight force of the frame parts 4, 5 only bears downon the columns 10 after placement and then does not further compress theadhesive 12.

The tool 1 with the parts 2, 3, 4, 5 of the roof fixed thereon can thenbe moved in the direction of the arrow 13, for example on rails or viainduction drive and induction control, and form the lower support of aroof installation tool 14 in which at least one of the frame parts 4, 5is connected to lateral linkage parts 15 which support the roof withrespect to the vehicle body with a completely installed roof.

In addition to the lower support, which is formed by the tool 1, thetool 14 includes an upper support 16 which accordingly supports thelinkage 15 upside down, but otherwise corresponding to its longitudinalposition and transverse position in the later vehicle and which islowerable in the direction of the arrow 17 (FIG. 12). This upper support16 can also be movable instead of the tool 1.

The linkage 15 is held at the support 16 via holders 18 in exactly thatangular position in which it will later hold the closed roof in thevehicle. It therefore tightly contacts the frame part 4 or 5 during theinstallation. The schematic representation in accordance with FIG. 4with a slightly opened parallelogram in the linkage 15 is only chosenfor better illustration.

The connection between the later upper end 19 of the linkage part andthe frame part 5 and/or 4 takes place in the lowered position of thesupport 16 in accordance with FIG. 13. Since the linkage 15 is held atthe support 16 practically free of tolerance with respect to thedimensions of the body and since the frame parts 4, 5 are held free oftolerance in the tool 1, a possible production tolerance between theparts can be compensated as required by an adapted number of washers 20,so-called shim packets. They can moreover be provided with elongateholes so that they can effect a tolerance compensation in two spatialdirections.

The tolerances are thus compensated inside the roof itself, its outerdimensions are exactly dimensionally stable with respect to the body,whereby the roof installation at the carcass is substantiallyfacilitated and accelerated.

Furthermore, connection members which hold the fully installed closedroof at the windshield frame can be installed at least at one frame part5 in its position turned upside down at the front end.

In this connection, a template 22 is put on almost free of tolerance, isin particular pivoted on in the direction of the arrow 24, for thealignment of the connection members to the front frame part 5, saidtemplate including centering devices 21 for its installation on theframe part 5. Screws or similar fastening means can be guided into thetemplate 22 in the state put on and fixed via the centering members 21for the exactly fitting fixing of the connection members, with thefastening means, for example, being able to adopt the precise positionpreset by the template 22 in elongate holes.

This template is a component of a roof closure installation tool 23which is in turn a component of the tool 1 in the embodiment drawn forthe exactly fitting holding of the frames 4, 5 in an upside downposition. The frame parts 4, 5 can thereby remain clamped up to the endof the roof installation without a relative movement to the tool 1 sothat the adhesive 12 has an extended hardening time. Furthermore, theexactly fitting alignment of the connection members of the roof tip isalso ensured since the template 22 is held in an exactly fitting mannerwith respect to the tool 1. The template 22 can be downwardly pivotedand thus release the contact surface of the parts for the insertion ofthe windows 2, 3 and frame parts 4, 5. The number of the processingsteps is moreover minimized by the remaining of the parts 2, 3, 4, 5 inthe tool 1, which increases the efficiency of the manufacture.

Since the tool 1 can both be connected to the roof installation tool 14and includes the roof closure installation tool 23, the tool effort inthe manufacturing process is moreover minimized. The tool 1 can, forexample, be supplied to the upper support 16 of the roof installationtool via rails or in an inductively controlled manner, with the mass ofthe car holding the tools 1 being so large that a dimensionally stableholding is ensured which is unmoved during the installation step.

The roof closure installation tool 14 can moreover be used independentlyof the roof installation tool 23. Both installation steps can thereforetake place simultaneously or shortly after one another, which shortensthe production time.

In any case, all the installation steps can be carried out by operatorsin an ergonomically favorable body posture; overhead work is notnecessary for any workstep.

It is understood in this connection that the manufacturing processes arenot restricted to those roofs which have a plurality of glass windows.As well, for example, for a RHT, in addition to the window 2 and itsframe part 4, a component can also be placed into the tool 1 with apreinstalled connection between, for example, a metal sheet and a framepart 5 or between a reference section and a frame part 5. Making theconnection only in the tool 1 is then not compulsory for these parts.

1-25. (canceled)
 26. A method of manufacturing a convertible roofincluding at least two frame parts each supporting an outer shell part,the method comprising the steps of: providing a lower tool fixtureincluding a first receiving plane and a second receiving plane spacedfrom the first receiving plane, the first receiving plane defining apath of travel along a predetermined length of the tool fixture; placingan outer shell part on the first receiving plane of the lower tool in anupside down relationship with respect to the roof's disposition on avehicle body; and placing a frame part on the second receiving plane ofthe lower tool fixture in an upside down relationship with respect tothe roof's disposition on a vehicle body.
 27. A method as set forth inclaim 26, further comprising the step of placing an adhesive bead on theouter shell part or the frame part; and wherein the step of placing theframe part on the second receiving plane comprises compressing theadhesive bead to achieve a predetermined distance between the outershell part and the frame part.
 28. A method as set forth in claim 26,wherein the step of placing an outer shell part on the first receivingplane comprises placing the outer shell parts on the first receivingplane of the lower tool fixture in side by side relationship and spacedapart from each other, the outer shell parts being in an upside downrelationship with respect to the roof's disposition on a vehicle body;and tile step of placing a frame part on the second receiving planecomprises placing the at least two frame parts on the second receivingplane of the lower tool fixture in an upside down relationship withrespect to the roof's disposition on a vehicle body.
 29. A method as setforth in claim 28, further comprising the step of placing an adhesivebead on each of the outer shell parts or on each of the frame parts; andwherein the step of placing the frame parts on the second receivingplane comprises compressing the adhesive bead to achieve a predetermineddistance between the outer shell parts and the frame parts.
 30. A methodas set forth in claim 29, wherein the step of placing an adhesive beadcomprises placing an adhesive bead around the periphery of the parts.31. A method as set forth in claim 28, further comprising the step ofproviding an abutment between the outer shell parts; and pushing atleast one of the outer shell parts towards the other along the path oftravel until the outer shell parts are in contact with the abutment. 32.A method as set forth in claim 28, further comprising the step of:providing a pair of lateral linkage parts; and fixing the pair oflateral linkage parts onto the assembled frame parts and outer shellparts.
 33. A method as set forth in claim 31, wherein the outer shellparts is a rear window and a passenger overhead panel, and the rearwindow is pushed along the path of travel of the first receiving planetowards the passenger overhead panel until both outer shell parts makecontact with the abutment.
 34. A method as set forth in claim 31,further comprising the step of providing a pushing member for pushingone of the outer shell parts along the path of travel.
 35. A method asset forth in claim 32, further comprising the step of providing a meansfor moving the assembled frame parts and outer shell parts to anotherarea whereby the linkage parts may be lowered and fixed thereon, themeans for moving selected from the group consisting of rails orinduction guides.
 36. A method as set forth in claim 32, furthercomprising the step of providing an upper tool fixture; holding thelinkage parts with the upper tool fixture; and moving one of either theupper tool fixture or the lower tool fixture towards the other therebyfixing the linkage parts onto the assembled frame parts and outershells.
 37. A method as set forth in claim 26, further comprising thestep of providing at least one gap filling device; and disposing the gapfilling device between where the linkage part and the frame part.
 38. Amethod as set forth in claim 37, wherein the gap filling device is awasher.
 39. A method as set forth in claim 28, further comprising thestep of providing at least one connection member for securing theconvertible roof to the windshield frame of a vehicle.
 40. A method asset forth in claim 39, wherein the lower tool fixture further includes atemplate for aligning and installing the connection member onto one ofthe frame parts.
 41. A tool for manufacturing a convertible roof, theconvertible roof including at least two frame parts each supporting anouter shell part, the tool comprising: a lower tool fixture that servesas a platform for the formation of the roof, the lower tool fixtureincluding a first receiving plane having a defined path of travel, thefirst receiving plane for supporting the outer shell parts in an upsidedown relationship with respect to the roof's disposition on a vehiclebody; the lower tool fixture further having a second receiving plane forsupporting the frame parts in an upside down relationship with respectto the roof's disposition on a vehicle body; wherein the secondreceiving plane is disposed above the first receiving plane atpredetermined distance.
 42. A tool as set forth in claim 41, wherein thefirst receiving plane includes a horizontal portion spaced apart from anoblique portion, wherein the oblique portion extends upwardly from thehorizontal portion, such that the horizontal portion and the obliqueportion are angled with respect to one another so as to present theposition of the convertible roof in the closed position when installedon a vehicle.
 43. A tool as set forth in claim 42, further comprising anabutment disposed between the horizontal and oblique portions of thefirst receiving plane.
 44. A tool as set forth in claim 41, wherein thesecond receiving plane further includes lateral holders extendingoutwardly from the lower tool fixture to hold the frame parts.
 45. Atool as set forth in claim 41, wherein the convertible roof furtherincludes lateral linkage parts, the tool further comprising an uppertool fixture for supporting the lateral linkage parts, the upper toolfixture movable between a first position and a second position, theupper tool fixture disposed above and spaced apart from the lower toolfixture in the first position such that the lateral linkage parts arealigned to the frame parts, and the upper tool fixture movable to thesecond position to fix the lateral linkage parts to the frame parts. 46.A tool as set forth in claim 43, further comprising a pushing member forengaging an outer shell part received on the oblique portion of thefirst receiving plane and pushing the window set on the oblique portionalong the defined path of travel until the window comes into contactwith the abutment.
 47. A tool as set forth in claim 41, wherein thepredetermined distance between the first receiving plane and the secondreceiving plane as measured perpendicular thereto, is between 5 and 9millimeters.
 48. A tool as set forth in claim 41, further comprising ameans for moving the lower tool fixture along a second path of travel,the means selected from the group consisting of rails or inductionguides.
 49. A tool as set forth in claim 41, wherein the convertibleroof further includes a connection member for connecting the roof to awindshield frame of the vehicle, the tool further comprising a templatedisposed on the lower tool fixture for receiving the connection memberand positioning the connection member such that the connection member isproperly aligned to the windshield frame of the vehicle when the roof isin the closed position.
 50. A tool as set forth in claim 49, furthercomprising a centering device for further aligning the connection memberon the frame part such that the connection member can engage thewindshield frame of the vehicle when the roof is in the closed position.51. A tool as set forth in claim 49, wherein the template is pivotablymounted.